Factors Affecting Tool Life In Machining

Processes
 What are these??

Factors Affecting Tool Life In Machining Processes

 ME 572
Analysis of Manufacturing Processes

Factors Affecting Tool Life

In Machining Processes

Mohammad AlJuhani
Introduction
Tool Life and Machinability
Tool Damage
Causes of tool damage
Factors Affecting Tool Life in Machining Processes

Factors Affecting Tool Life In Machining Processes

• Cuttingtool life is important consideration in metal cutting
processes.

• In machining operations, cutting conditions such as tool angles,

cutting speeds and feed rates are usually selected to give an
economical tool life.

• Conditions giving a short tool life are uneconomical because

tool grinding and tool replacement costs are high.

• Factorsaffecting tool life should be carefully monitored to

minimize their consequences.

Factors Affecting Tool Life In Machining Processes

Tool Life and Machinability

• A tool that doesn’t perform the desired function can be declared as

failed, or reached the end of its useful life.

• At this point of time, the tool is not necessarily unable to cut the
workpiece but is merely unsatisfactory (may not give the desired
surface finish or dimensional tolerances) for the purpose required

• The tool life is defined as the length of cutting time that the tool
can be used.

Factors Affecting Tool Life In Machining Processes

Tool Damage

• Tool damage can be classified into two groups, wear and fracture by means of its scale
and how it progresses.

• Wear is loss of material on an asperity or micro-contact, or smaller scale, down to

molecular or atomic removal mechanisms. It usually progresses continuously.

• There are two main types of tool wear

• Flank wear
• Crater wear

• Fracture, on the other hand, is damage at a larger scale than wear and it occurs
suddenly.

Factors Affecting Tool Life In Machining Processes

Tool damage. Flank wear vs. cutting time

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Mechanical Damage

Thermal Damage

Adhesion

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Mechanical Damage

It is independent of temperature.

Mechanical
Damage

Abrasion Chipping Fracture Fatigue

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Mechanical Damage

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

It increases drastically with increasing

temperature

Plastic
deformation

Thermal
Damage
Chemical
reaction Diffusion

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Factors Affecting Tool Life In Machining Processes

Causes of tool damage
Adhesion Damage

Occurs when work or chip material welds to

the tool surface.

Factors Affecting Tool Life In Machining Processes

Causes of tool damage

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Geometry

Cutting Fluid Cutting Tool

Material

Factors
Affecting
Tool Life
Workpiece Cutting Tool
Material. Characteristic
s

Cutting
Conditions

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Geometry

Power and
Surface finish
speed of
requirements.
machine

Type of Geometry of
operation being Workpiece
cutting tool material,
performed, varies with

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Geometry

Magnitude and
direction of the
Chip cutting forces
Tool life.
control.

Productivity
Distribution of
of
the thermal
machining.
energy

Cutting
tool Temperature
Machined
distribution in
surface geometry the cutting
quality. is directly wedge
affects

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Geometry

Factors Affecting Tool Life In Machining Processes

Rake angle Cutting Tool
Geometry
Rake angles are three types, positive, zero and negative.
For ductile materials, the rake inclination is a positive angle
Since their shearing is low.
For brittle materials, the rake inclination is a negative angle.
The advantages of increasing rake angle
• Reduces the horsepower consumption.
• The cutting force and tool-chip contact temperature change in
approximately the same way.
The disadvantages of increasing rake angle
• The strength of the cutting wedge decreases when the rake angle
increases.
• The region of the maximum contact temperature at the tool-chip
interface shifts toward the cutting edge.

Factors Affecting Tool Life In Machining Processes

Flank angle Cutting Tool
Geometry
The flank angle affects the performance of the cutting tool
mainly by decreasing the rubbing between the tool
surface and workpiece surface.

With increasing the flank angle the following advantages

are obtained:
• Cutting edge radius decreases which leads to decrease in
the frictional and deformation components of the flank
force.
• The strength of the region adjacent to the cutting edge
decreases.
• Heat dissipates through the tool decreases.

Factors Affecting Tool Life In Machining Processes

Nose Radius Cutting Tool
Geometry
Nose radius is very critical part of the cutting edge.

If the radius is made of sharp angle, the produced finished surface will
be rough and tool life will be short.

A large nose radius benefits

• Better surface finish.
• Faster feed rate.
• Stronger tool.
• Allow faster cutting speed

However, large radii have negative sequences such as tool chatter.

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
The cutting operation Material
involved
Factors affecting selection
cutting tool material
Workpiece material

Production
requirements

Surface finish and

accuracy requirements.

Machine to be used

Factors Affecting Tool Life In Machining Processes

 Resistance to heat Cutting Tool
Material
(hot hardness)

Resistance to
mechanical impact
thermal shock.

Major qualities required Resistance to wear

in a cutting tool (hardness)

Resistance to fracture
(toughness)

Chemical stability to the

workpiece material

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Material

Factors Affecting Tool Life In Machining Processes

 Improve Cutting Tool
wear Material
resistance

Cutting
Tool
Coating
Reduce Reduce
frictional thermal
contact. conductivity.

Today, 50% of HSS, 85% of carbide and 40% of super-hard tools

used in industry are coated

Factors Affecting Tool Life In Machining Processes

 Cutting Tool
Material

Uncoated cutting tool Coated cutting tool

Factors Affecting Tool Life In Machining Processes
 Pressure resistance. Cutting Tool
Characteristics

To stand against high stress Bending strength.

Cutting Tool Characteristics

Edge strength.

Inner bonding strength.

High temperature strength.

Small propensity to diffusion and

adhesion (Chemically stable).

Abrasion resistance.

Reproducible wear behavior.

Factors Affecting Tool Life In Machining

Processes
 Cutting
Conditions

Depth of cut

Feed rate

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Depth of cut has least effect upon tool life, so the heaviest (10 times the
feed rate) possible depth of cut should always be used.

Depth of cut is limited by

• Amount of metal to be machined from the workpiece,
• Power available on machine tool,
• Rigidity of the work piece and cutting tool
• Rigidity of the setup.
• Workpiece configuration
• Insert size & thickness

Factors Affecting Tool Life In Machining Processes

 Depth of cut

Cutting
Feed rate
Conditions

Cutting Speed

Factors Affecting Tool Life In Machining Processes

 Workpiece
Material.
Tool life

Energy
Surface
(power)
roughness
consumption
Machinability
of workpiece
criteria

Magnitude of
Surface
cutting
integrity
forces

Factors Affecting Tool Life In Machining Processes

 Workpiece
Material.
Chemical
composition.
Heat
Fabrication
treatment.

Yield and
Grain size. tensile
strength.

Factors
determine
Microstructure. conditions of Hardness
the work
material

Factors Affecting Tool Life In Machining Processes

 Cutting
Fluid

Main Cutting
Fluid Functions

Removing chips
Lubrication effect Cooling effect away from the
cutting zone

Factors Affecting Tool Life In Machining Processes

 Reduction of cutting forces/ Cutting
energy consumptions. Fluid

Improvement of surface finish

Other functions of cutting fluids
and dimensional accuracy.

Extend tool life.

Facilitate chip removal.

Corrosion prevention on
workpiece and machines.

Lowering workpiece
temperature.

Lubrication of machine tool

sliding guides

Factors Affecting Tool Life In Machining Processes

 Good lubricating
properties
Cutting
Fluid
High cooling capacity

Low viscosity to provide

free flow of cutting fluid.

Cutting fluids properties

Chemically stable.

Non-corrosive.

High flash point to reduce

fire risks.

Allergy free.

Less evaporative.

Low cost.

Factors Affecting Tool Life In Machining Processes

 Cutting
Fluid

Cutting Fluids
Selection

Type of
Type of machining machined Type of cutting
processes. workpiece tool material.
material.

Factors Affecting Tool Life In Machining Processes

 Cutting
Fluid
Biodegradability

Life cycle
assessment

Bioaccumulability
Cutting Fluid Effects

Environmental and
biomagnifications

Energy saving and

fuel economy

Renewability

Respiratory
problems.
Health
Dermatological
problems

Factors Affecting Tool Life In Machining Processes

 Cutting
Fluid

Environmental
machining

Minimum Vegetable
Dry cutting quantity based cutting
lubricant fluids

Factors Affecting Tool Life In Machining Processes

Factors Affecting Tool Life In Machining Processes
Factors Affecting Tool Life In Machining
Processes
 Cutting Tool
Geometry

Factors Affecting Tool Life In Machining Processes